Scion 2005-06

Master Cylinder

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Overhaul



  1. Remove the clutch master cylinder from the vehicle, as outlined in this section, and mount it in a suitable vise.
  2.  
  3. Using a pin punch and a hammer, drive out the slotted spring pin.

    Click image to see an enlarged view

    Fig. Using a pin punch and a hammer, drive out the slotted spring pin

  4.  
  5. Remove the inlet union and the grommet.
  6.  
  7. Loosen the lock nut, and remove the push rod clevis.
  8.  
  9. Remove the lock nut from the push rod.
  10.  
  11. Remove the boot from the cylinder body.
  12.  
  13. Using snap ring pliers, remove the snap ring while pushing on the piston rod.

    Click image to see an enlarged view

    Fig. Using snap ring pliers, remove the snap ring while pushing on the piston rod

  14.  
  15. Remove the push rod from the cylinder body.
    NOTE
    The piston may pop out of the cylinder body. Therefore, slowly remove the push rod from the cylinder body.

  16.  
  17. Remove the stop plate from the push rod.
  18.  
  19. Remove the piston with spring from the cylinder.
    NOTE
    Be careful not to damage the inside of the cylinder body.

  20.  

To install:

  1. Coat the parts shown in the illustration with lithium soap base glycol grease.

    Click image to see an enlarged view

    Fig. Coat the parts shown with arrows with lithium soap base glycol grease

  2.  
  3. Install the piston with spring into the cylinder.
    NOTE
    Be careful not to damage the inside of the cylinder body.

  4.  
  5. Install the stop plate to the push rod.
  6.  
  7. Install the push rod to the cylinder body.
  8.  
  9. Using snap ring pliers, install the snap ring while pushing on the piston rod.

    Click image to see an enlarged view

    Fig. Using snap ring pliers, install the snap ring while pushing on the piston rod

  10.  
  11. Install the boot on the cylinder body.
  12.  
  13. Install the lock nut on the push rod.
  14.  
  15. Temporarily install the clevis with the lock nut to the push rod.
  16.  
  17. Install the inlet union and a new grommet.
  18.  
  19. Using a pin punch and a hammer, drive in the slotted spring pin:
    1. Protrusion: 1.5 to 3.5 mm (0.059 to 0.138 in.)

      Click image to see an enlarged view

      Fig. Drive in the slotted spring pin. When correctly installed, there should be a protrusion of 1.5-3.5mm

    2.  

  20.  
  21. Install clutch master cylinder assembly, as outlined in this section.
  22.  

  1. Remove the clutch master cylinder from the vehicle, as outlined in this section, and mount it in a suitable vise.
  2.  
  3. Using a pin punch and a hammer, drive out the slotted spring pin.

    Click image to see an enlarged view

    Fig. Using a pin punch and a hammer, drive out the slotted spring pin

  4.  
  5. Remove the inlet union and grommet.
  6.  
  7. Loosen the lock nut, and remove the clevis.
  8.  
  9. Remove the lock nut from the push rod.
  10.  
  11. Remove the boot from the cylinder body.
  12.  
  13. Using snap ring pliers, remove the snap ring while pushing on the piston rod.

    Click image to see an enlarged view

    Fig. Using snap ring pliers, remove the snap ring while pushing on the piston rod

  14.  
  15. Remove the push rod from the cylinder body.
    NOTE
    The piston may pop up out of the cylinder body. Therefore, slowly remove the push rod from the cylinder body.

  16.  
  17. Remove the stop plate from the push rod.
  18.  
  19. Remove the piston with the spring from the cylinder.
    WARNING
    Be careful not to damage the inside of the cylinder body.

  20.  

To install:

  1. Coat the parts shown in the illustration with lithium soap base glycol grease.

    Click image to see an enlarged view

    Fig. Coat the parts indicated by arrows with lithium soap base glycol grease

  2.  
  3. Install the piston with the spring into the cylinder.
    NOTE
    Be careful not to damage the inside of the cylinder body.

  4.  
  5. Install the stop plate to the push rod.
  6.  
  7. Install the push rod to the cylinder body.
  8.  
  9. Using snap ring pliers, install the snap ring while pushing on the piston rod.
  10.  
  11. Install the boot to the cylinder body.
  12.  
  13. Install the lock nut to the push rod.
  14.  
  15. Temporarily install the clevis with the lock nut to the push rod.
  16.  
  17. Install the inlet union and a new grommet.
  18.  
  19. Using a pin punch and a hammer, drive in the slotted spring pin. The protrusion should be: 1.5 to 3.5 mm (0.059 to 0.138 in.).
  20.  
  21. When driving in the slotted spring pin, then proper protrusion should be 1.5-3.5mm
  22.  
  23. Install the clutch master cylinder assembly, as outlined in this section.
  24.  

Removal & Installation



  1. Remove the brake master cylinder assembly.
  2.  
  3. Remove the brake actuator.
  4.  
  5. Remove the brake booster.
  6.  
  7. Remove the clutch pedal spring
  8.  
  9. Remove clutch master cylinder push rod clevis with hole pin. Remove the clip and the hole pin.

    Click image to see an enlarged view

    Fig. Remove clutch master cylinder push rod clevis with hole pin. Remove the clip and the hole pin

  10.  
  11. Drain the clutch fluid
    WARNING
    Wash brake fluid off immediately if it contacts any painted surface. Brake fluid will eat through paint!

  12.  
  13. Loosen the clip and remove the clutch reservoir tube from the clutch master cylinder .
    NOTE
    Use a container or rag to catch any fluid that leaks out.



    Click image to see an enlarged view

    Fig. Loosen the clip and remove the clutch reservoir tube from the clutch master cylinder

  14.  
  15. Disconnect the clutch master cylinder to flexible hose tube:
    1. Using SST 09023-00101, or equivalent tool, disconnect the flexible hose tube.
      NOTE
      Use a container or rag to catch any fluid that leaks out.



      Click image to see an enlarged view

      Fig. Disconnect the clutch master cylinder to flexible hose tube

    2.  

  16.  
  17. Remove the 2 nuts, then remove the clutch master cylinder .
  18.  

To install:

  1. Install the clutch master cylinder with the 2 nuts and tighten to 9 ft. lbs. (12 Nm).
  2.  
  3. Connect clutch master cylinder to flexible hose tube, using the special tool. Tighten to 11 ft. lbs. (15 Nm).
  4.  
  5. Install the clutch reservoir tube
  6.  
  7. Connect the clutch reservoir tube with the clip to the clutch master cylinder .
    NOTE
    Connect the clutch reservoir tube, taking care not to twist it. Make sure the white mark is facing upward.

  8.  
  9. Install clutch master cylinder push rod clevis w/hole pin:
    1. Apply mp grease to the contact surface of the hole pin and the clevis bush.
    2.  
    3. Connect the clevis to the clutch pedal sub-with the hole pin.
      NOTE
      Install the hole pin from the left side of the vehicle.

    4.  
    5. Install the clip to the hole pin.
    6.  

  10.  
  11. Install the clutch pedal spring
  12.  
  13. Install the brake booster.
  14.  
  15. Install the brake actuator.
  16.  
  17. Install the brake master cylinder.
  18.  
  19. Bleed the brakes, as outlined in the Brake Section
  20.  
  21. Bleed the clutch system, as outlined in this section.
  22.  
  23. Inspect for any fluid leakage in the clutch and/or brake system.
  24.  
  25. Check the fluid level in the reservoir and add as necessary.
  26.  
  27. Inspect and adjust clutch pedal, as outlined under Clutch Adjustments in this section.
  28.  

  1. Use a syringe or other suitable tool to drain the clutch fluid from the reservoir.
    WARNING
    Wash brake fluid off immediately if it contacts any painted surface. Brake fluid will eat through paint!

  2.  
  3. Remove the brake master cylinder assembly.
  4.  
  5. Remove the brake booster.
  6.  
  7. Loosen the clip and disconnect the clutch reservoir tube from the clutch master cylinder .
    NOTE
    Use a container or rag to catch any fluid that leaks out.



    Click image to see an enlarged view

    Fig. Loosen the clip and disconnect the clutch reservoir tube from the clutch master cylinder

  8.  
  9. Disconnect the clutch master cylinder-to-flexible hose tube using SST 09023-00101, or equivalent tool.
    NOTE
    Use a container or rag to catch any fluid that leaks out.



    Click image to see an enlarged view

    Fig. Use the special tool to disconnect the clutch master cylinder-to-flexible hose tube

  10.  
  11. Remove clutch master cylinder push rod clevis with hole pin by removing the clip.
  12.  
  13. Remove the 2 nuts, then remove the clutch master cylinder from the vehicle.
  14.  

To install:

  1. Install the clutch master cylinder with the 2 nuts and tighten to 9 ft. lbs. (12 Nm).
  2.  
  3. Install clutch master cylinder push rod clevis with hole pin, as follows:
    1. Apply mp grease to the contact surface of the hole pin and clevis bush.
    2.  
    3. Connect the clevis to the clutch pedal sub-with the hole pin.
      NOTE
      Install the hole pin from the right side of the vehicle.

    4.  
    5. Install the clip to the hole pin.
    6.  

  4.  
  5. Connect clutch master cylinder to flexible hose tube, using the special tool and tighten to 11 ft. lbs. (15 Nm).
  6.  
  7. Connect the clutch reservoir tube with the clip to the clutch master cylinder , making sure the red mark faces upward
  8.  
  9. Install the brake booster.
  10.  
  11. Install the brake master cylinder.
  12.  
  13. Bleed the brakes, as outlined in the Brake Section
  14.  
  15. Fill the fluid reservoir tank with clutch fluid and bleed the clutch system, as outlined in this section.
  16.  
  17. Check and adjust brake pedal height.
  18.  
  19. Inspect and adjust clutch pedal, as outlined under Clutch Adjustments.
  20.  
  21. Inspect for any fluid leakage in the clutch and/or brake system.
  22.  
  23. Check the fluid level in the reservoir and add as necessary.
  24.  
  25. Inspect and adjust clutch pedal, as outlined under Clutch Adjustments in this section.
  26.  

 
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